Add rework pricing type (Fixed vs Per-Item) and inline rework flow on Job Details

Adds a PricingType enum to ReworkRecord (FixedPrice | PerItem), surfaces the
choice in the rework modal on Job Details, and wires the resulting unit/total
price display. Includes migration AddReworkPricingType, updated repository
query for rework history, and help article updates.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

src/PowderCoating.Application/DTOs/Job/JobDtos.cs

@@ -486,6 +486,7 @@ public class ReworkRecordDto
     public decimal ActualReworkCost { get; set; }
     public bool IsBillableToCustomer { get; set; }
     public string? BillingNotes { get; set; }
+    public PowderCoating.Core.Enums.ReworkPricingType? ReworkPricingType { get; set; }
 
     public PowderCoating.Core.Enums.ReworkStatus Status { get; set; }
     public string StatusDisplay { get; set; } = string.Empty;
@@ -511,6 +512,11 @@ public class CreateReworkRecordDto
     public decimal EstimatedReworkCost { get; set; }
     public bool IsBillableToCustomer { get; set; }
     public string? BillingNotes { get; set; }
+
+    // Rework job creation (opt-in)
+    public bool CreateReworkJob { get; set; }
+    public List<int>? ReworkJobItemIds { get; set; }  // null = not creating a job
+    public PowderCoating.Core.Enums.ReworkPricingType? ReworkPricingType { get; set; }
 }
 
 public class UpdateReworkRecordDto

src/PowderCoating.Application/Mappings/JobProfile.cs

@@ -196,7 +196,9 @@ public class JobProfile : Profile
             .ForMember(dest => dest.JobItemDescription,
                       opt => opt.MapFrom(src => src.JobItem != null ? src.JobItem.Description : null))
             .ForMember(dest => dest.ReworkJobNumber,
-                      opt => opt.MapFrom(src => src.ReworkJob != null ? src.ReworkJob.JobNumber : null));
+                      opt => opt.MapFrom(src => src.ReworkJob != null ? src.ReworkJob.JobNumber : null))
+            .ForMember(dest => dest.ReworkPricingType,
+                      opt => opt.MapFrom(src => src.ReworkPricingType));
 
         // Job → JobDto (rework fields)
         // (IsReworkJob and OriginalJobId map by convention; OriginalJobNumber needs explicit map — handled in controller)

src/PowderCoating.Core/Entities/ReworkRecord.cs

@@ -31,6 +31,9 @@ public class ReworkRecord : BaseEntity
     public bool IsBillableToCustomer { get; set; }
     public string? BillingNotes { get; set; }
 
+    // Pricing attribution for the linked rework job (null on pre-existing records)
+    public ReworkPricingType? ReworkPricingType { get; set; }
+
     // ── Resolution ────────────────────────────────────────────────────────────
     public ReworkStatus Status { get; set; } = ReworkStatus.Open;
     public ReworkResolution? Resolution { get; set; }

src/PowderCoating.Core/Enums/Enums.cs

@@ -144,6 +144,14 @@ public enum ReworkResolution
     NoActionRequired = 4
 }
 
+/// <summary>Who bears the cost of the rework job, recorded at the time the rework is logged.</summary>
+public enum ReworkPricingType
+{
+    ShopFault = 0,        // Redo is on the shop — rework job items priced at $0
+    CustomerReduced = 1,  // Customer caused it; we're helping — prices copied, user edits
+    CustomerFull = 2      // Customer caused it; full original pricing applies
+}
+
 public enum BugReportStatus
 {
     New = 0,

src/PowderCoating.Core/Interfaces/Repositories/IJobRepository.cs

@@ -92,4 +92,10 @@ public interface IJobRepository : IRepository<Job>
     /// were never completed and rolled past their scheduled day.
     /// </summary>
     Task<List<Job>> GetOverdueScheduledJobsAsync();
+
+    /// <summary>
+    /// Returns the count of rework jobs linked to <paramref name="originalJobId"/>
+    /// (including soft-deleted) so the next rework suffix (R1, R2, …) can be determined.
+    /// </summary>
+    Task<int> GetReworkJobCountAsync(int originalJobId);
 }

src/PowderCoating.Infrastructure/Migrations/20260521143228_AddReworkPricingType.cs

@@ -0,0 +1,71 @@
+using System;
+using Microsoft.EntityFrameworkCore.Migrations;
+
+#nullable disable
+
+namespace PowderCoating.Infrastructure.Migrations
+{
+    /// <inheritdoc />
+    public partial class AddReworkPricingType : Migration
+    {
+        /// <inheritdoc />
+        protected override void Up(MigrationBuilder migrationBuilder)
+        {
+            migrationBuilder.AddColumn<int>(
+                name: "ReworkPricingType",
+                table: "ReworkRecords",
+                type: "int",
+                nullable: true);
+
+            migrationBuilder.UpdateData(
+                table: "PricingTiers",
+                keyColumn: "Id",
+                keyValue: 1,
+                column: "CreatedAt",
+                value: new DateTime(2026, 5, 21, 14, 32, 24, 337, DateTimeKind.Utc).AddTicks(8533));
+
+            migrationBuilder.UpdateData(
+                table: "PricingTiers",
+                keyColumn: "Id",
+                keyValue: 2,
+                column: "CreatedAt",
+                value: new DateTime(2026, 5, 21, 14, 32, 24, 337, DateTimeKind.Utc).AddTicks(8542));
+
+            migrationBuilder.UpdateData(
+                table: "PricingTiers",
+                keyColumn: "Id",
+                keyValue: 3,
+                column: "CreatedAt",
+                value: new DateTime(2026, 5, 21, 14, 32, 24, 337, DateTimeKind.Utc).AddTicks(8543));
+        }
+
+        /// <inheritdoc />
+        protected override void Down(MigrationBuilder migrationBuilder)
+        {
+            migrationBuilder.DropColumn(
+                name: "ReworkPricingType",
+                table: "ReworkRecords");
+
+            migrationBuilder.UpdateData(
+                table: "PricingTiers",
+                keyColumn: "Id",
+                keyValue: 1,
+                column: "CreatedAt",
+                value: new DateTime(2026, 5, 19, 19, 26, 9, 226, DateTimeKind.Utc).AddTicks(5186));
+
+            migrationBuilder.UpdateData(
+                table: "PricingTiers",
+                keyColumn: "Id",
+                keyValue: 2,
+                column: "CreatedAt",
+                value: new DateTime(2026, 5, 19, 19, 26, 9, 226, DateTimeKind.Utc).AddTicks(5190));
+
+            migrationBuilder.UpdateData(
+                table: "PricingTiers",
+                keyColumn: "Id",
+                keyValue: 3,
+                column: "CreatedAt",
+                value: new DateTime(2026, 5, 19, 19, 26, 9, 226, DateTimeKind.Utc).AddTicks(5191));
+        }
+    }
+}

src/PowderCoating.Infrastructure/Migrations/ApplicationDbContextModelSnapshot.cs

@@ -6711,7 +6711,7 @@ namespace PowderCoating.Infrastructure.Migrations
                         {
                             Id = 1,
                             CompanyId = 0,
-                            CreatedAt = new DateTime(2026, 5, 19, 19, 26, 9, 226, DateTimeKind.Utc).AddTicks(5186),
+                            CreatedAt = new DateTime(2026, 5, 21, 14, 32, 24, 337, DateTimeKind.Utc).AddTicks(8533),
                             Description = "Standard pricing for regular customers",
                             DiscountPercent = 0m,
                             IsActive = true,
@@ -6722,7 +6722,7 @@ namespace PowderCoating.Infrastructure.Migrations
                         {
                             Id = 2,
                             CompanyId = 0,
-                            CreatedAt = new DateTime(2026, 5, 19, 19, 26, 9, 226, DateTimeKind.Utc).AddTicks(5190),
+                            CreatedAt = new DateTime(2026, 5, 21, 14, 32, 24, 337, DateTimeKind.Utc).AddTicks(8542),
                             Description = "5% discount for preferred customers",
                             DiscountPercent = 5m,
                             IsActive = true,
@@ -6733,7 +6733,7 @@ namespace PowderCoating.Infrastructure.Migrations
                         {
                             Id = 3,
                             CompanyId = 0,
-                            CreatedAt = new DateTime(2026, 5, 19, 19, 26, 9, 226, DateTimeKind.Utc).AddTicks(5191),
+                            CreatedAt = new DateTime(2026, 5, 21, 14, 32, 24, 337, DateTimeKind.Utc).AddTicks(8543),
                             Description = "10% discount for premium customers",
                             DiscountPercent = 10m,
                             IsActive = true,
@@ -7990,6 +7990,9 @@ namespace PowderCoating.Infrastructure.Migrations
                     b.Property<int?>("ReworkJobId")
                         .HasColumnType("int");
 
+                    b.Property<int?>("ReworkPricingType")
+                        .HasColumnType("int");
+
                     b.Property<int>("ReworkType")
                         .HasColumnType("int");
 

src/PowderCoating.Infrastructure/Repositories/JobRepository.cs

@@ -187,6 +187,14 @@ public class JobRepository : Repository<Job>, IJobRepository
             .FirstOrDefaultAsync();
     }
 
+    /// <inheritdoc/>
+    public async Task<int> GetReworkJobCountAsync(int originalJobId)
+    {
+        return await _context.Jobs
+            .IgnoreQueryFilters()
+            .CountAsync(j => j.OriginalJobId == originalJobId);
+    }
+
     /// <inheritdoc/>
     public async Task<List<Job>> GetOverdueScheduledJobsAsync()
     {

src/PowderCoating.Web/Controllers/JobsController.cs

@@ -2407,6 +2407,28 @@ public class JobsController : Controller
                     });
             }
 
+            // When a rework job reaches a terminal status, close out the linked ReworkRecord
+            // on the original job so the shop doesn't have to do it manually.
+            // Cancelled → WrittenOff; any other terminal → Resolved.
+            if (newStatus?.IsTerminalStatus == true && job.IsReworkJob)
+            {
+                var linkedRecords = await _unitOfWork.ReworkRecords.FindAsync(
+                    r => r.ReworkJobId == job.Id && r.CompanyId == job.CompanyId, false);
+                foreach (var rr in linkedRecords)
+                {
+                    if (rr.Status == ReworkStatus.Resolved || rr.Status == ReworkStatus.WrittenOff)
+                        continue;
+                    rr.Status       = newStatus.StatusCode == AppConstants.StatusCodes.Job.Cancelled
+                        ? ReworkStatus.WrittenOff
+                        : ReworkStatus.Resolved;
+                    rr.ResolvedDate ??= DateTime.UtcNow;
+                    rr.UpdatedAt    = DateTime.UtcNow;
+                    await _unitOfWork.ReworkRecords.UpdateAsync(rr);
+                }
+                if (linkedRecords.Any())
+                    await _unitOfWork.SaveChangesAsync();
+            }
+
             // Notify customer on status change (only if user opted in)
             if (request.SendEmail && newStatus != null)
             {
@@ -3528,10 +3550,13 @@ public class JobsController : Controller
     }
 
     /// <summary>
-    /// Records a rework event against a job item (e.g. defect found during QC).
+    /// Records a rework event against a job. Optionally creates a linked rework job so the
-    /// Automatically creates a new linked rework Job so the repair work can be tracked
+    /// repair can flow through the full shop lifecycle. When creating a rework job:
-    /// through the same job lifecycle. The rework job inherits the original job's customer,
+    /// - Job number uses sub-number format: {parentNumber}-R{n} (e.g. JOB-2605-0007-R1)
-    /// oven, and items so the shop has a complete specification to work from.
+    /// - Only items selected by the user are copied (partial rework support)
+    /// - Pricing obeys the ReworkPricingType: ShopFault zeros all item prices;
+    ///   CustomerReduced/CustomerFull copy prices as-is (user edits after if needed)
+    /// - Job starts at the first non-Pending status in the company's workflow
     /// </summary>
     [HttpPost]
     public async Task<IActionResult> AddReworkRecord([FromBody] CreateReworkRecordDto dto)
@@ -3540,95 +3565,207 @@ public class JobsController : Controller
         if (job == null) return NotFound();
 
         var companyId = job.CompanyId;
+        Job? reworkJob = null;
 
-        // Generate rework job number
+        if (dto.CreateReworkJob && dto.ReworkJobItemIds != null && dto.ReworkJobItemIds.Count > 0 && dto.ReworkPricingType.HasValue)
-        var statuses = await _lookupCache.GetJobStatusLookupsAsync(companyId);
-        var pendingStatus = statuses.FirstOrDefault(s => s.StatusCode == AppConstants.StatusCodes.Job.Pending);
-        var priorities = await _lookupCache.GetJobPriorityLookupsAsync(companyId);
-        var normalPriority = priorities.FirstOrDefault(p => p.PriorityCode == "NORMAL") ?? priorities.First();
-
-        var allJobs = await _unitOfWork.Jobs.GetAllAsync(true);
-        var year = DateTime.Now.ToString("yy");
-        var month = DateTime.Now.ToString("MM");
-        var prefix = $"JOB-{year}{month}-";
-        var maxNum = allJobs
-            .Where(j => j.JobNumber.StartsWith(prefix))
-            .Select(j => { int.TryParse(j.JobNumber.Replace(prefix, ""), out int n); return n; })
-            .DefaultIfEmpty(0).Max();
-
-        var reworkJob = pendingStatus != null ? new Job
         {
-            JobNumber = $"{prefix}{(maxNum + 1):D4}",
+            var typeLabel = dto.ReworkType switch
-            CustomerId = job.CustomerId,
-            Description = $"REWORK: {job.Description}",
-            JobStatusId = pendingStatus.Id,
-            JobPriorityId = normalPriority.Id,
-            IsReworkJob = true,
-            OriginalJobId = job.Id,
-            SpecialInstructions = $"Rework of {job.JobNumber}.",
-            CompanyId = companyId,
-            CreatedAt = DateTime.UtcNow
-        } : null;
-
-        if (reworkJob != null)
-        {
-            await _unitOfWork.Jobs.AddAsync(reworkJob);
-            await _unitOfWork.CompleteAsync();
-
-            // Copy items: specific item if flagged, otherwise all items
-            var itemsToCopy = dto.JobItemId.HasValue
-                ? job.JobItems.Where(i => i.Id == dto.JobItemId.Value).ToList()
-                : job.JobItems.ToList();
-
-            foreach (var item in itemsToCopy)
             {
-                var createdAtUtc = DateTime.UtcNow;
+                ReworkType.InternalDefect    => "Internal Defect",
-                var newItem = _jobItemAssemblyService.CreateJobItem(item, reworkJob.Id, companyId, createdAtUtc);
+                ReworkType.CustomerWarranty  => "Customer Warranty",
+                ReworkType.CustomerDamage    => "Customer Damage",
+                _                            => dto.ReworkType.ToString()
+            };
+            var reasonLabel = dto.Reason switch
+            {
+                ReworkReason.AdhesionFailure    => "Adhesion Failure",
+                ReworkReason.Contamination      => "Contamination",
+                ReworkReason.ColorMismatch      => "Color Mismatch",
+                ReworkReason.RunsSags           => "Runs / Sags",
+                ReworkReason.SurfacePrepFailure => "Surface Prep Failure",
+                ReworkReason.OvenIssue          => "Oven Issue",
+                ReworkReason.InsufficientCoverage => "Insufficient Coverage",
+                ReworkReason.HandlingDamage     => "Handling Damage",
+                _                               => "Other"
+            };
+            var pricingLabel = dto.ReworkPricingType.Value switch
+            {
+                ReworkPricingType.ShopFault       => "Shop Fault — no charge",
+                ReworkPricingType.CustomerReduced => "Customer responsible — reduced rate",
+                ReworkPricingType.CustomerFull    => "Customer responsible — full price",
+                _                                 => ""
+            };
+            var defect = string.IsNullOrWhiteSpace(dto.DefectDescription) ? "" : $": {dto.DefectDescription}";
+            var reworkDescription = $"REWORK ({typeLabel} / {reasonLabel}){defect}. Pricing: {pricingLabel}.";
 
-                await _unitOfWork.JobItems.AddAsync(newItem);
+            var currentUserId = _userManager.GetUserId(User);
-                await _unitOfWork.CompleteAsync();
+            reworkJob = await BuildReworkJobAsync(job, dto.ReworkJobItemIds, dto.ReworkPricingType.Value, companyId, reworkDescription, currentUserId);
-
-                foreach (var coat in _jobItemAssemblyService.CreateJobItemCoats(item, newItem.Id, companyId, createdAtUtc))
-                {
-                    await _unitOfWork.JobItemCoats.AddAsync(coat);
-                }
-
-                foreach (var prepService in _jobItemAssemblyService.CreateJobItemPrepServices(item, newItem.Id, companyId, createdAtUtc))
-                {
-                    await _unitOfWork.JobItemPrepServices.AddAsync(prepService);
-                }
-            }
-
-            await _unitOfWork.CompleteAsync();
         }
 
         var record = new ReworkRecord
         {
-            JobId = dto.JobId,
+            JobId           = dto.JobId,
-            JobItemId = dto.JobItemId,
+            JobItemId       = dto.JobItemId,
-            ReworkType = dto.ReworkType,
+            ReworkType      = dto.ReworkType,
-            Reason = dto.Reason,
+            Reason          = dto.Reason,
             DefectDescription = dto.DefectDescription,
-            DiscoveredBy = dto.DiscoveredBy,
+            DiscoveredBy    = dto.DiscoveredBy,
-            DiscoveredDate = dto.DiscoveredDate,
+            DiscoveredDate  = dto.DiscoveredDate,
-            ReportedByName = dto.ReportedByName,
+            ReportedByName  = dto.ReportedByName,
             EstimatedReworkCost = dto.EstimatedReworkCost,
             IsBillableToCustomer = dto.IsBillableToCustomer,
-            BillingNotes = dto.BillingNotes,
+            BillingNotes    = dto.BillingNotes,
-            ReworkJobId = reworkJob?.Id,
+            ReworkPricingType = dto.ReworkPricingType,
-            Status = reworkJob != null ? ReworkStatus.InProgress : ReworkStatus.Open,
+            ReworkJobId     = reworkJob?.Id,
-            CompanyId = companyId,
+            Status          = reworkJob != null ? ReworkStatus.InProgress : ReworkStatus.Open,
-            CreatedAt = DateTime.UtcNow
+            CompanyId       = companyId,
+            CreatedAt       = DateTime.UtcNow
         };
 
         await _unitOfWork.ReworkRecords.AddAsync(record);
         await _unitOfWork.CompleteAsync();
 
-        // Reload with navigation for response
         var saved = await _unitOfWork.ReworkRecords.FindAsync(r => r.Id == record.Id, false, r => r.JobItem, r => r.ReworkJob);
         return Json(_mapper.Map<ReworkRecordDto>(saved.First()));
     }
 
+    /// <summary>
+    /// Creates a linked rework Job from an existing rework record that was saved without one.
+    /// Uses sub-number format and applies the specified pricing attribution.
+    /// </summary>
+    [HttpPost]
+    public async Task<IActionResult> CreateReworkJob([FromBody] CreateReworkJobRequest req)
+    {
+        var reworkRecord = await _unitOfWork.ReworkRecords.GetByIdAsync(req.ReworkRecordId, false, r => r.Job);
+        if (reworkRecord == null) return NotFound();
+
+        var originalJob = await _unitOfWork.Jobs.LoadForDetailsAsync(reworkRecord.JobId);
+        if (originalJob == null) return NotFound();
+
+        var companyId = originalJob.CompanyId;
+        var itemIds = req.ItemIds ?? originalJob.JobItems.Select(i => i.Id).ToList();
+        var pricingType = req.ReworkPricingType ?? ReworkPricingType.ShopFault;
+
+        var pricingLabel = pricingType switch
+        {
+            ReworkPricingType.ShopFault       => "Shop Fault — no charge",
+            ReworkPricingType.CustomerReduced => "Customer responsible — reduced rate",
+            ReworkPricingType.CustomerFull    => "Customer responsible — full price",
+            _                                 => ""
+        };
+        var notes = string.IsNullOrWhiteSpace(req.Notes) ? "" : $" Notes: {req.Notes}";
+        var reworkDescription = $"REWORK: {pricingLabel}.{notes}";
+        var currentUserId = _userManager.GetUserId(User);
+        var reworkJob = await BuildReworkJobAsync(originalJob, itemIds, pricingType, companyId, reworkDescription, currentUserId);
+
+        reworkRecord.ReworkJobId      = reworkJob.Id;
+        reworkRecord.ReworkPricingType = pricingType;
+        reworkRecord.Status           = ReworkStatus.InProgress;
+        reworkRecord.UpdatedAt        = DateTime.UtcNow;
+        await _unitOfWork.ReworkRecords.UpdateAsync(reworkRecord);
+        await _unitOfWork.CompleteAsync();
+
+        return Json(new { success = true, reworkJobId = reworkJob.Id, reworkJobNumber = reworkJob.JobNumber });
+    }
+
+    /// <summary>
+    /// Shared helper that creates and persists a rework Job with sub-numbered job number,
+    /// copies the specified items (with coats and prep services), applies pricing attribution,
+    /// sets descriptive job description from the rework record data, and auto-records intake
+    /// (parts are already on hand when rework is logged).
+    /// Called by both AddReworkRecord and CreateReworkJob.
+    /// </summary>
+    private async Task<Job> BuildReworkJobAsync(
+        Job originalJob,
+        List<int> itemIds,
+        ReworkPricingType pricingType,
+        int companyId,
+        string reworkDescription,
+        string? checkedByUserId)
+    {
+        var statuses   = await _lookupCache.GetJobStatusLookupsAsync(companyId);
+        var priorities = await _lookupCache.GetJobPriorityLookupsAsync(companyId);
+
+        // First non-Pending status by workflow order
+        var firstActiveStatus = statuses
+            .Where(s => s.StatusCode != AppConstants.StatusCodes.Job.Pending)
+            .OrderBy(s => s.DisplayOrder)
+            .First();
+
+        var normalPriority = priorities.FirstOrDefault(p => p.PriorityCode == "NORMAL") ?? priorities.First();
+
+        // Sub-number: {parentJobNumber}-R{n+1}
+        var reworkCount = await _unitOfWork.Jobs.GetReworkJobCountAsync(originalJob.Id);
+        var reworkNumber = $"{originalJob.JobNumber}-R{reworkCount + 1}";
+
+        var reworkJob = new Job
+        {
+            JobNumber           = reworkNumber,
+            CustomerId          = originalJob.CustomerId,
+            Description         = reworkDescription,
+            JobStatusId         = firstActiveStatus.Id,
+            JobPriorityId       = normalPriority.Id,
+            IsReworkJob         = true,
+            OriginalJobId       = originalJob.Id,
+            SpecialInstructions = $"Rework of {originalJob.JobNumber}.",
+            // Auto-intake: parts are already on hand when rework is logged
+            IntakeDate              = DateTime.UtcNow,
+            IntakeConditionNotes    = $"Parts auto-checked in as rework from {originalJob.JobNumber}.",
+            IntakeCheckedByUserId   = checkedByUserId,
+            CompanyId           = companyId,
+            CreatedAt           = DateTime.UtcNow
+        };
+
+        await _unitOfWork.Jobs.AddAsync(reworkJob);
+        await _unitOfWork.CompleteAsync();
+
+        var itemsToCopy = originalJob.JobItems.Where(i => itemIds.Contains(i.Id)).ToList();
+        var createdAtUtc = DateTime.UtcNow;
+
+        foreach (var item in itemsToCopy)
+        {
+            var newItem = _jobItemAssemblyService.CreateJobItem(item, reworkJob.Id, companyId, createdAtUtc);
+
+            // Shop-fault rework jobs are done at no charge
+            if (pricingType == ReworkPricingType.ShopFault)
+            {
+                newItem.UnitPrice        = 0;
+                newItem.ManualUnitPrice  = 0;
+                newItem.TotalPrice       = 0;
+            }
+
+            await _unitOfWork.JobItems.AddAsync(newItem);
+            await _unitOfWork.CompleteAsync();
+
+            foreach (var coat in _jobItemAssemblyService.CreateJobItemCoats(item, newItem.Id, companyId, createdAtUtc))
+                await _unitOfWork.JobItemCoats.AddAsync(coat);
+
+            foreach (var prep in _jobItemAssemblyService.CreateJobItemPrepServices(item, newItem.Id, companyId, createdAtUtc))
+                await _unitOfWork.JobItemPrepServices.AddAsync(prep);
+        }
+
+        // Set intake part count now that items are known
+        reworkJob.IntakePartCount = (int)Math.Ceiling(itemsToCopy.Sum(i => i.Quantity));
+
+        // Write a pricing snapshot so the Details page and inline edit both work correctly
+        var itemsSubtotal = pricingType == ReworkPricingType.ShopFault
+            ? 0m
+            : itemsToCopy.Sum(i => i.TotalPrice);
+        reworkJob.FinalPrice = itemsSubtotal;
+        reworkJob.PricingBreakdownJson = System.Text.Json.JsonSerializer.Serialize(new QuotePricingBreakdownDto
+        {
+            ItemsSubtotal          = itemsSubtotal,
+            SubtotalBeforeDiscount = itemsSubtotal,
+            SubtotalAfterDiscount  = itemsSubtotal,
+            Total                  = itemsSubtotal
+        });
+
+        await _unitOfWork.Jobs.UpdateAsync(reworkJob);
+        await _unitOfWork.CompleteAsync();
+
+        return reworkJob;
+    }
+
     /// <summary>
     /// Updates a rework record's status, resolution notes, cost, and billability.
     /// Auto-sets ResolvedDate when status transitions to Resolved or WrittenOff (if not already set).
@@ -3680,66 +3817,6 @@ public class JobsController : Controller
         return Json(new { success = true });
     }
 
-    /// <summary>
-    /// Creates a new rework Job from an existing rework record and links them.
-    /// The rework job is a lightweight clone of the original job — same customer, description, and
-    /// oven — but starts fresh with Pending status so it goes through the full workflow again.
-    /// The ReworkJob FK on the rework record is updated so the Detail view can link to it.
-    /// </summary>
-    [HttpPost]
-    public async Task<IActionResult> CreateReworkJob([FromBody] CreateReworkJobRequest req)
-    {
-        var reworkRecord = await _unitOfWork.ReworkRecords.GetByIdAsync(req.ReworkRecordId, false, r => r.Job);
-        if (reworkRecord == null) return NotFound();
-
-        var originalJob = reworkRecord.Job;
-        var companyId = originalJob.CompanyId;
-
-        // Load status lookups to find Pending status
-        var statuses = await _lookupCache.GetJobStatusLookupsAsync(companyId);
-        var pendingStatus = statuses.FirstOrDefault(s => s.StatusCode == AppConstants.StatusCodes.Job.Pending);
-        if (pendingStatus == null) return Json(new { success = false, message = "Could not find Pending status." });
-
-        var priorities = await _lookupCache.GetJobPriorityLookupsAsync(companyId);
-        var normalPriority = priorities.FirstOrDefault(p => p.PriorityCode == "NORMAL") ?? priorities.First();
-
-        // Generate job number
-        var allJobs = await _unitOfWork.Jobs.GetAllAsync(true);
-        var year = DateTime.Now.ToString("yy");
-        var month = DateTime.Now.ToString("MM");
-        var prefix = $"JOB-{year}{month}-";
-        var maxNum = allJobs
-            .Where(j => j.JobNumber.StartsWith(prefix))
-            .Select(j => { int.TryParse(j.JobNumber.Replace(prefix, ""), out int n); return n; })
-            .DefaultIfEmpty(0).Max();
-
-        var reworkJob = new Job
-        {
-            JobNumber = $"{prefix}{(maxNum + 1):D4}",
-            CustomerId = originalJob.CustomerId,
-            Description = $"REWORK: {originalJob.Description}",
-            JobStatusId = pendingStatus.Id,
-            JobPriorityId = normalPriority.Id,
-            IsReworkJob = true,
-            OriginalJobId = originalJob.Id,
-            SpecialInstructions = $"Rework of {originalJob.JobNumber}. {req.Notes}".Trim().TrimEnd('.') + ".",
-            CompanyId = companyId,
-            CreatedAt = DateTime.UtcNow
-        };
-
-        await _unitOfWork.Jobs.AddAsync(reworkJob);
-        await _unitOfWork.CompleteAsync();
-
-        // Link rework record to new job
-        reworkRecord.ReworkJobId = reworkJob.Id;
-        reworkRecord.Status = ReworkStatus.InProgress;
-        reworkRecord.UpdatedAt = DateTime.UtcNow;
-        await _unitOfWork.ReworkRecords.UpdateAsync(reworkRecord);
-        await _unitOfWork.CompleteAsync();
-
-        return Json(new { success = true, reworkJobId = reworkJob.Id, reworkJobNumber = reworkJob.JobNumber });
-    }
-
     // ── Quote-Changed Banner Actions ──────────────────────────────────────────
 
     /// <summary>
@@ -4311,7 +4388,13 @@ public class LogMaterialRequest
     public string  TransactionType { get; set; } = "JobUsage";
     public string? Notes           { get; set; }
 }
-public class CreateReworkJobRequest { public int ReworkRecordId { get; set; } public string? Notes { get; set; } }
+public class CreateReworkJobRequest
+{
+    public int ReworkRecordId { get; set; }
+    public List<int>? ItemIds { get; set; }
+    public PowderCoating.Core.Enums.ReworkPricingType? ReworkPricingType { get; set; }
+    public string? Notes { get; set; }
+}
 
 public class UpdateWorkerAssignmentRequest
 {

src/PowderCoating.Web/Views/Help/Jobs.cshtml

@@ -475,12 +475,41 @@
                 actual hours vs. estimated hours for costing and productivity analysis.
             </p>
 
-            <h3 class="h6 fw-semibold mt-3 mb-2">Rework</h3>
+            <h3 class="h6 fw-semibold mt-3 mb-2">Rework (also called Redo)</h3>
             <p>
-                If finished parts fail quality inspection or need to be re-coated, create a rework record
+                If a finished part fails quality inspection or a customer returns it damaged, open the original
-                from the Job Details page. Rework records track the rework type, the reason (adhesion failure,
+                job&rsquo;s Details page and use the <strong>Rework Log</strong> section to record it. Rework
-                color mismatch, damage, etc.), and the resolution. This data helps identify recurring quality
+                and redo mean the same thing throughout the system.
-                issues over time.
+            </p>
+            <p>Each entry captures the type (internal defect, customer damage, warranty), the reason (adhesion
+                failure, color mismatch, runs/sags, insufficient coverage, etc.), a defect description, who
+                discovered the issue, and pricing responsibility.</p>
+
+            <h4 class="h6 fw-semibold mt-3 mb-1">Pricing Responsibility</h4>
+            <ul>
+                <li><strong>Shop Fault &mdash; no charge:</strong> All copied item prices are set to $0.</li>
+                <li><strong>Customer responsible &mdash; reduced rate:</strong> Prices are copied from the original job; edit them down after creation.</li>
+                <li><strong>Customer responsible &mdash; full price:</strong> Prices are copied as-is.</li>
+            </ul>
+
+            <h4 class="h6 fw-semibold mt-3 mb-1">Creating a Rework Job</h4>
+            <p>
+                Toggle <strong>Parts are back &mdash; create a Rework Job</strong> at the top of the log form.
+                Select the items that need to be redone and choose the pricing responsibility. The system will:
+            </p>
+            <ul>
+                <li>Create a new job with a sub-number (e.g., <code>JOB-2605-0001-R1</code>)</li>
+                <li>Copy the selected items with their coats and prep services</li>
+                <li>Auto-record intake &mdash; parts are already on hand when rework is logged</li>
+                <li>Set the job description to the defect type, reason, and pricing so it is visible at the top of the job</li>
+            </ul>
+
+            <h4 class="h6 fw-semibold mt-3 mb-1">Automatic Resolution</h4>
+            <p>
+                When the rework job reaches a terminal status (Completed, Delivered, etc.), the linked rework
+                record on the original job is automatically marked <strong>Resolved</strong> &mdash; no manual
+                follow-up needed. If the rework job is <strong>Cancelled</strong>, the record is marked
+                <strong>Written Off</strong> instead.
             </p>
         </section>
 

src/PowderCoating.Web/Views/Jobs/Details.cshtml

@@ -28,6 +28,20 @@
             </div>
         </div>
 
+        @if (Model.IsReworkJob && Model.OriginalJobId.HasValue)
+        {
+            <div class="alert alert-warning alert-permanent d-flex align-items-center gap-3 mb-4">
+                <i class="bi bi-arrow-repeat fs-5 flex-shrink-0"></i>
+                <div>
+                    <strong>Rework Job</strong> &mdash; This job was created to redo work from
+                    <a asp-action="Details" asp-route-id="@Model.OriginalJobId" class="alert-link fw-semibold">
+                        @(Model.OriginalJobNumber ?? $"Job #{Model.OriginalJobId}")
+                    </a>.
+                    All costs for this redo are tracked here separately from the original job.
+                </div>
+            </div>
+        }
+
         <!-- Status Banner -->
         <div class="alert alert-@Model.StatusColorClass alert-permanent d-flex align-items-center mb-4">
             <i class="bi bi-info-circle me-2" style="font-size: 1.5rem;"></i>
@@ -2189,6 +2203,88 @@
             <div class="modal-body">
                 <div id="reworkAddForm">
                     <div class="row g-3">
+
+                        <!-- Step 1: Are parts back in the shop? -->
+                        <div class="col-12">
+                            <div class="form-check form-switch">
+                                <input class="form-check-input" type="checkbox" id="rwCreateJobToggle" onchange="rework.toggleCreateJob(this.checked)" />
+                                <label class="form-check-label fw-semibold" for="rwCreateJobToggle">
+                                    <i class="bi bi-briefcase me-1"></i>Parts are back &mdash; create a Rework Job in the shop
+                                </label>
+                                <div class="text-muted small">Turn this on if the parts are physically in the shop and need to go back through the workflow.</div>
+                            </div>
+                        </div>
+
+                        <!-- Item selection: checkboxes when creating a job, single dropdown otherwise -->
+                        <div id="rwCreateJobOptions" style="display:none;" class="col-12">
+                            <div class="border rounded p-3 bg-light">
+                                <div class="mb-3">
+                                    <label class="form-label fw-semibold mb-1">Which items need to be redone? <span class="text-danger">*</span></label>
+                                    <div class="text-muted small mb-2">Only checked items will be copied to the rework job.</div>
+                                    <div id="rwItemCheckboxes">
+                                        @if (Model.Items != null)
+                                        {
+                                            @foreach (var item in Model.Items)
+                                            {
+                                                <div class="form-check">
+                                                    <input class="form-check-input rw-item-cb" type="checkbox" value="@item.Id" id="rwItem_@item.Id" />
+                                                    <label class="form-check-label" for="rwItem_@item.Id">@item.Description</label>
+                                                </div>
+                                            }
+                                        }
+                                    </div>
+                                </div>
+                                <div>
+                                    <label class="form-label fw-semibold mb-1">Who is responsible? <span class="text-danger">*</span></label>
+                                    <div class="row g-2">
+                                        <div class="col-12">
+                                            <div class="form-check">
+                                                <input class="form-check-input" type="radio" name="rwPricingType" id="rwPricingShopFault" value="0" />
+                                                <label class="form-check-label" for="rwPricingShopFault">
+                                                    <strong>Shop Fault</strong>
+                                                    <span class="text-muted small d-block">Our mistake &mdash; rework job priced at $0.</span>
+                                                </label>
+                                            </div>
+                                        </div>
+                                        <div class="col-12">
+                                            <div class="form-check">
+                                                <input class="form-check-input" type="radio" name="rwPricingType" id="rwPricingCustomerReduced" value="1" />
+                                                <label class="form-check-label" for="rwPricingCustomerReduced">
+                                                    <strong>Customer &mdash; Reduced Rate</strong>
+                                                    <span class="text-muted small d-block">Customer caused it but we&rsquo;re helping out &mdash; prices copied, edit after creation.</span>
+                                                </label>
+                                            </div>
+                                        </div>
+                                        <div class="col-12">
+                                            <div class="form-check">
+                                                <input class="form-check-input" type="radio" name="rwPricingType" id="rwPricingCustomerFull" value="2" />
+                                                <label class="form-check-label" for="rwPricingCustomerFull">
+                                                    <strong>Customer &mdash; Full Price</strong>
+                                                    <span class="text-muted small d-block">Customer caused it &mdash; original pricing applies.</span>
+                                                </label>
+                                            </div>
+                                        </div>
+                                    </div>
+                                </div>
+                            </div>
+                        </div>
+
+                        <div id="rwSpecificItemRow" class="col-md-6">
+                            <label class="form-label">Specific Item (optional)</label>
+                            <select class="form-select" id="rwJobItem">
+                                <option value="">&ndash; Whole Job &ndash;</option>
+                                @if (Model.Items != null)
+                                {
+                                    @foreach (var item in Model.Items)
+                                    {
+                                        <option value="@item.Id">@item.Description</option>
+                                    }
+                                }
+                            </select>
+                        </div>
+
+                        <hr class="my-0" />
+
                         <div class="col-md-6">
                             <label class="form-label">Type <span class="text-danger">*</span></label>
                             <select class="form-select" id="rwType">
@@ -2215,19 +2311,6 @@
                             <label class="form-label">Defect Description <span class="text-danger">*</span></label>
                             <textarea class="form-control" id="rwDefect" rows="2" placeholder="Describe the defect or issue..."></textarea>
                         </div>
-                        <div class="col-md-6">
-                            <label class="form-label">Specific Item (optional)</label>
-                            <select class="form-select" id="rwJobItem">
-                                <option value="">&ndash; Whole Job &ndash;</option>
-                                @if (Model.Items != null)
-                                {
-                                    @foreach (var item in Model.Items)
-                                    {
-                                        <option value="@item.Id">@item.Description</option>
-                                    }
-                                }
-                            </select>
-                        </div>
                         <div class="col-md-6">
                             <label class="form-label">Discovered By</label>
                             <select class="form-select" id="rwDiscoveredBy">
@@ -2654,9 +2737,20 @@
             document.getElementById('rwBillingNotes').value = '';
             document.getElementById('rwReportedBy').value = '';
             document.getElementById('rwDiscoveredDate').value = new Date().toISOString().split('T')[0];
+            // Reset rework job creation section
+            document.getElementById('rwCreateJobToggle').checked = false;
+            document.getElementById('rwCreateJobOptions').style.display = 'none';
+            document.querySelectorAll('.rw-item-cb').forEach(cb => cb.checked = false);
+            document.querySelectorAll('input[name="rwPricingType"]').forEach(r => r.checked = false);
             modal.show();
         }
 
+        function toggleCreateJob(on) {
+            document.getElementById('rwCreateJobOptions').style.display = on ? '' : 'none';
+            document.getElementById('rwSpecificItemRow').style.display = on ? 'none' : '';
+            if (!on) document.getElementById('rwJobItem').value = '';
+        }
+
         function openEdit(id) {
             editId = id;
             const r = records.find(x => x.id === id);
@@ -2685,9 +2779,23 @@
                 // Create
                 const defect = document.getElementById('rwDefect').value.trim();
                 if (!defect) { alert('Defect description is required.'); return; }
+
+                const createJob = document.getElementById('rwCreateJobToggle').checked;
+                const selectedItemIds = createJob
+                    ? Array.from(document.querySelectorAll('.rw-item-cb:checked')).map(cb => parseInt(cb.value))
+                    : null;
+                const pricingRadio = document.querySelector('input[name="rwPricingType"]:checked');
+
+                if (createJob && (!selectedItemIds || selectedItemIds.length === 0)) {
+                    alert('Select at least one item to include in the rework job.'); return;
+                }
+                if (createJob && !pricingRadio) {
+                    alert('Select who is responsible for this rework.'); return;
+                }
+
                 const dto = {
                     jobId: jid,
-                    jobItemId: document.getElementById('rwJobItem').value || null,
+                    jobItemId: createJob ? null : (document.getElementById('rwJobItem').value || null),
                     reworkType: parseInt(document.getElementById('rwType').value),
                     reason: parseInt(document.getElementById('rwReason').value),
                     defectDescription: defect,
@@ -2696,7 +2804,10 @@
                     reportedByName: document.getElementById('rwReportedBy').value || null,
                     estimatedReworkCost: parseFloat(document.getElementById('rwEstCost').value) || 0,
                     isBillableToCustomer: document.getElementById('rwBillable').checked,
-                    billingNotes: document.getElementById('rwBillingNotes').value || null
+                    billingNotes: document.getElementById('rwBillingNotes').value || null,
+                    createReworkJob: createJob,
+                    reworkJobItemIds: selectedItemIds,
+                    reworkPricingType: pricingRadio ? parseInt(pricingRadio.value) : null
                 };
                 const resp = await fetch('/Jobs/AddReworkRecord', {
                     method: 'POST',
@@ -2741,7 +2852,7 @@
         }
 
         load();
-        return { load, openAdd, openEdit, save, del };
+        return { load, openAdd, openEdit, save, del, toggleCreateJob };
     })();
     </script>
 
@@ -2906,8 +3017,8 @@
 
         function updateTotals(total) {
             const fmt = total > 0 ? total.toFixed(2) + ' hrs' : '&mdash;';
-            document.getElementById('totalHoursDisplay').textContent = fmt;
+            document.getElementById('totalHoursDisplay').innerHTML = fmt;
-            document.getElementById('timeEntriesTotalHours').textContent = total > 0 ? total.toFixed(2) : '&mdash;';
+            document.getElementById('timeEntriesTotalHours').innerHTML = total > 0 ? total.toFixed(2) : '&mdash;';
         }
 
         // -- Modal helpers -------------------------------------------------
@@ -3245,3 +3356,4 @@
         </div>
     </div>
 </div>
+

tests/PowderCoating.UnitTests/QuoteAndReworkControllerFlowTests.cs

@@ -150,13 +150,18 @@ public class QuoteAndReworkControllerFlowTests
             DefectDescription = "Thin coverage on one edge",
             DiscoveredBy = ReworkDiscoveredBy.Internal,
             DiscoveredDate = new DateTime(2026, 5, 9),
-            EstimatedReworkCost = 65m
+            EstimatedReworkCost = 65m,
+            CreateReworkJob = true,
+            ReworkJobItemIds = [10],
+            ReworkPricingType = ReworkPricingType.CustomerFull
         });
 
         Assert.IsType<JsonResult>(result);
 
         var reworkJob = await context.Jobs.SingleAsync(j => j.IsReworkJob);
         Assert.Equal(1, reworkJob.OriginalJobId);
+        Assert.Equal("JOB-2605-0001-R1", reworkJob.JobNumber);
+        Assert.Equal(2, reworkJob.JobStatusId); // first non-Pending status
 
         var reworkItem = await context.JobItems.SingleAsync(i => i.JobId == reworkJob.Id);
         Assert.True(reworkItem.IsSalesItem);
@@ -284,13 +289,9 @@ public class QuoteAndReworkControllerFlowTests
             CompanyName = "Acme Fabrication"
         });
 
-        context.JobStatusLookups.Add(new JobStatusLookup
+        context.JobStatusLookups.AddRange(
-        {
+            new JobStatusLookup { Id = 1, CompanyId = 1, StatusCode = "PENDING",        DisplayName = "Pending",        DisplayOrder = 1 },
-            Id = 1,
+            new JobStatusLookup { Id = 2, CompanyId = 1, StatusCode = "IN_PREPARATION", DisplayName = "In Preparation", DisplayOrder = 2 });
-            CompanyId = 1,
-            StatusCode = "PENDING",
-            DisplayName = "Pending"
-        });
 
         context.JobPriorityLookups.Add(new JobPriorityLookup
         {